TRADE OF

Industrial Insulation
PHASE 2

Module 6

Insulation & Cladding The Training Rig

UNIT: 1

Measuring the Training Rig

 Produced by

In cooperation with subject matter expert:

Michael Kelly

© SOLAS 2014
Module 6– Unit 1 Measuring the Training Rig

Table of Contents
Introduction .................................................................................................................. 1 
Unit Objective .............................................................................................................. 2 
1.0  Measuring and Sketching............................................................................... 3 
1.1  Pipe-Work Systems .....................................................................................3 
1.2  Information on Pipes .................................................................................3 
1.3  Tubes ............................................................................................................3 
1.4  Pipe Sizes......................................................................................................4 
1.5  General Information on Measuring Steel Butt-Welded Pipe Fittings .4 
1.6  Measuring a “Gate” Valve .........................................................................6 
1.7  Measuring a Flanged joint/ Flange box ...................................................8 
1.8  Radius Elbows .............................................................................................9 
1.9  Measuring Vessels .......................................................................................9 
2.0  The Training Rig ........................................................................................... 10 
2.1  Isometric Drawing of the Training Rig .................................................10 
2.2  Units of Measurement – Metric and Imperial ......................................12 
2.3  Approximate use of Tolerance on Dimensions ...................................12 
2.4  Use of a Plumb-Line and Spirit Level....................................................12 
2.5  Accurate Centre Finding ..........................................................................12 
2.6  Calculation and Application of Insulation Allowances .......................13 
2.7  Area Calculation ........................................................................................13 
2.8  Joint Positioning in Insulation and Cladding ........................................13 
2.9  Obstacle Location on Pipe-Work ...........................................................14 
3.0  Measuring Pipe-work and job Planning .................................................... 15 
3.1  Use and Care of Measuring Equipment ................................................15 
3.2  Pipe Circumferences .................................................................................16 
3.3  Callipers ......................................................................................................16 
3.4  Job Planning, Teamwork and Record Keeping ....................................17 
Summary ...................................................................................................................... 18 

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Module 6– Unit 1 Measuring the Training Rig

Introduction
Pipe-work systems or pipe-lines are the arteries of Industry and through these
arteries fluids, vapours, gases, slurries, powders and solids flow in a multitude
of conditions imposed by plant processes. They are subjected to intense
pressures imposed by temperature, pressure and the flow of substances. These
systems also have to deal with the hazards such as corrosion, erosion, fire and
explosion, to toxic conditions and to diverse problems involving hygiene,
bacterial growth, heat and cold losses, handling of acids, alkalis, solvents and a
combination of these in various combinations.

Module 6
Insulating &
Cladding the
Training Rig

Unti 1 Unit 2 Unit 3 Unit 4 Unit 5

Measuring the Measuring the Insulation of the Substructure & Cladding of
Training Rig Training Rig Training Rig Support Training Rig
(Hot & Cold Systems
Work)

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Module 6– Unit 1 Measuring the Training Rig

Unit Objective
By the end of this unit each apprentice will be able to:
 Measure pipe work, valves and vessels for insulation and cladding.
 Sketch various ductwork forms.
 Read and interpret a works specification and a works drawing.
 Determine the material requirements for the insulation and cladding of
the training rig.

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1.0 Measuring and Sketching

Key Learning Points
 Accurate bare surface measuring.

1.1 Pipe-Work Systems

A pipeline or pipe-work system is usually made up of various diameter pipes
and fittings. These fittings would include 90 and 45 degree radius bends,
reducers (concentric and eccentric), tees (equal and unequal), hangers and
supports, and various types of valves to regulate and control flow. Pipes and
fittings can be welded together or flanged and bolted. Other methods of fixing
and connection pipes and fittings are also available.
Pipes and fittings are available in a wide range of materials such as stainless
steel, copper, brass, bronze, aluminium, various alloys and other metals and
non-metals.

1.2 Information on Pipes

Pipe is specified by stating its nominal size and it should be noted particularly
that the nominal size is only approximate, and is neither the inside or the
outside diameter and standard tables or manufacturers’ tables should be used to
ascertain exactly these two dimensions. Pipes over 14 inches (356mm) are
generally specified on the outside diameter and wall thickness. To explain how
this works, if you purchase a 2" pipe (this is the nominal; size), this pipe will
have an outside diameter of 2.375 inches ( 60.325mm). For pipes up to 12 inch
diameter, the nominal diameter is very loosely related to the inside diameter. As
mentioned above pipes of 14 inches (356mm) and over are generally specified
on outside diameter and wall thickness. It is important to mention that the wall
thickness of pipes of the same diameter can be different, but the outside
diameters will always be the same. This is to facilitate the connection of various
parts of pipe-line systems such as bends, tees, valves etc.

1.3 Tubes
It is worth mentioning that sometimes pipes are referred to as tubes and the
reverse also applies. Tubes, particularly those in copper and brass and in some
cases steel, nickel, and other metals and non-metals, are manufactured and
marketed on the basis of actual outside diameter and wall thickness and, as they
are drawn in a variety of thicknesses , both must be specified.

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1.4 Pipe Sizes

The pipe sizes used in various Industrial and commercial installations and
which need to be covered with insulation and cladding are as follows:
½" 21mm OD 7" 194mm OD
¾" 27mm OD 8" 219mm OD
1" 34mm OD 9" 245mm OD
1¼" 42mm OD 10" 273mm OD
1½" 48mm OD 12" 324mm OD
2" 60mm OD 14" 356mm OD
2½" 76mm OD 16" 406mm OD
3" 89mm OD 18" 456mm OD
4" 114mm OD 20" 508mm OD
5" 141mm OD 24" 610mm OD
6" 168mm OD

1.5 General Information on Measuring Steel

Butt-Welded Pipe Fittings
90º Long Radius Elbow

The “A” dimension is found by taking the nominal diameter of the elbow and
multiplying it by 1.5.
Example: 2" (nominal diameter) x 1.5 = 3"
Convert 3" to milimeters = 3 x 25.4 = 76.2mm.
Therefore “A” = 3" or 76mm (76.2mm rounded down).

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Module 6– Unit 1 Measuring the Training Rig

Concentric Reducer

For the length “H” of the reducer it is always advised to consult the
manufacturers’ catalogues.
Example: 2½" (nominal diameter) reducing to 2" (nominal diameter.
“H” = 3½" or 89mm (from manufacturers’ catalogue)

Eccentric Reducer of Flat-Back Reducer

For the length “H” of the reducer it is always advised to consult the
manufacturers’ catalogues.
Example: 2½" (nominal diameter) reducing to 2" (nominal diameter.
“H” = 3½" or 89mm (from manufacturers’ catalogue)

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Module 6– Unit 1 Measuring the Training Rig

1.6 Measuring a “Gate” Valve

Shown in the figure above is a “gate” valve. The measurements required to
manufacture a valve box for this type of valve are as follows:
A = The length between the outside of the flanges. When we are
manufacturing the valve box we have to add a clearance for the bolts to be
removed in case of replacement or maintenance. We also have to add to this
measurement for the thickness of the insulation.
B = The diameter of the pipe. We add to this diameter the thickness of
insulation (x2) fitted on the pipe plus the thickness (x2) of any cladding fitted
over the insulation. Allow a small allowance on the diameter of the hole cut out
of the valve box for ease of fitting over the valve.
C = Centre of the pipe to the top of the valve box. It is important to allow
enough room between the hand-wheel and the valve box for ease of operation
of the hand-wheel/ valve.
D = The diameter of the casting at the top of the valve. Add a small allowance
to the diameter of the hole cut out of the valve box for ease of fitting of the
box.
E = Diameter of flanges plus a clearance must be added for the insulation to be
fitted to the inside of the box.

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1.7 Measuring a Flanged joint/ Flange box

The measuring for a flange box is very straight forward. Firstly measure the
diameter and total thickness of the assembled flanges and then the bolts
holding them together. Space is required to permit bolt withdrawal without
disturbing the pipe insulation. Allow extra space within the box for pipe
insulation to be fitted. See the figure below for details of a completed flange
box.

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Module 6– Unit 1 Measuring the Training Rig

1.8 Radius Elbows

When cladding 90º radius elbows or indeed any pipe-work or fittings,
ductwork, vessels etc, it is very important that joints should be arranged to shed
water. The figure below shows elbows that have been cladded and how they are
designed and designated “A B C D” for ease of measuring and manufacture.
For elbows A and B the patterns are swaged on the head of the patterns, and
for elbows C and D the patterns are swaged on the tail of the patterns. It is
important to remember that the designations ABCD are when you are looking
at them as shown with the longitudinal joints on the near side, however if you
were looking at them from the far side the designations would change.

1.9 Measuring Vessels

Refer to module 5 – unit 7 – Vessels (storage and high pressure).

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2.0 The Training Rig

Key Learning Points
 Units of measurement: metric vs imperial
 Appropriate use of tolerance on dimensions
 Use of a plumb-line and spirit level
 Calculation and application of insulation allowances
 Accurate centre finding
 3D sketching: isometric and oblique
 Area calculation
 Joint positioning in insulation and cladding
 Obstacle location on pipe-work

2.1 Isometric Drawing of the Training Rig

The figure above shows an isometric drawing of the training rig. For the
purpose of this exercise we will only consider leg 1 for bare surface measuring.
Starting at the floor level as shown, measure:

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Module 6– Unit 1 Measuring the Training Rig

1. Diameter of pipe (ø 60mm OD) x length of pipe from flange at floor level
to flanged joint. Cladding should be shortened for bolt removal.
2. Flange diameters plus overall thickness of flanged joint.
3. Length of bolts securing flanged joint – this is to allow for the withdrawal
of the bolts without disturbing the insulation and cladding.
4. Flange box – see information above for measuring a flange box.
5. From flanged joint to weld at ø 60mm “B” type 90º elbow/bend.
6. 90º “B” type elbow/bend ø 60mm OD with a centreline radius of 3" or
76mm.
7. Concentric reducer – ø76/60mm x 3½/89mm long.
8. 90º “C” type elbow/bend – ø76mm OD with a centreline radius of 3¾" or
95mm.
9. ø 76mm OD pipe x length between welds of elbows.
10. 90º “B” type elbow/bend – ø76mm OD with a centreline radius of 3¾"
or 95mm.
11. ø 76mm OD pipe x length from “” type elbow/bend to valve.
12. Valve box – see information on measuring a valve box in section 1.6
above.
13. ø 76mm OD pipe x length from valve to weld at “C” type elbow/bend.
14. ø 27mm OD pipe – we will return to this item later.
15. 90º “C” type elbow/bend – ø 76mm OD with a centreline radius of 3¾"
or 95mm.
16. (16) ø 76mm OD pipe x length between welds of elbows.
17. (17) 90º “B” type elbow/bend – ø 76mm OD with a centreline radius of
3¾" or 95mm.
18. (18) ø 76mm OD pipe x length between “B” type elbow/bend and
concentric reducer.
19. (19) Concentric reducer - ø76/89mm x 3½/89mm long.
20. (20) ø 89mm OD pipe x length between concentric reducer and “A” type
90º elbow/bend.
21. (21) 90º “A” type elbow/bend ø 89mm OD with a centreline radius of
4½" or 114mm.
22. (22) Valve box – see information on measuring a valve box in section
1.6 above.
Note: On account of the close arrangement between the 90º elbow and the
valve, the valve box will have to encapsulate or enclose both the bend and the
valve in the one valve box. This will simplify the cladding arrangement at this
point in the pipeline.
23. (23) Tee-piece – ø89mm pipe onto ø168mm pipe.

Item 14 Above
(a) ø27mm OD pipe x length from the centre of the ø76mm OD pipe to “D”
type elbow. A tee-piece will be required at this point.
(b) 90º “D” type bend ø27mm OD with a centreline radius of 28.5mm. A
square elbow bend is required here due to the tight centreline radius.

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Module 6– Unit 1 Measuring the Training Rig

(c) ø27mm OD pipe x length from centre of ø76mm OD pipe to “C” type
bend. A tee-piece will be required at this junction.

2.2 Units of Measurement – Metric and

Imperial
Metric
10 millimetres (mm) =1 centimetre (cm)
100 centimetres (cm) =1 metre (m)
1000 millimetres (mm) =1 metre (m)

Imperial
12 inches (in or ") = 1 foot (ft or ')

British to metric Units

1 in = 2.54 cm = 25.4 mm

Metric to British Units

1 millimetre = 0.039 inch
1 centimetre = 0.394 inch
1 metre = 39.37 inches

2.3 Approximate use of Tolerance on

Dimensions
Tolerance is the amount of variation permitted on a dimension. The tolerance
is equal to the difference between the maximum and minimum limits of any
specified dimension. For example: if the tolerance on a piece of metal cladding
of 120mm diameter is ±2mm, this means that the cladding can be a maximum
of 122mm diameter or 118 minimum diameter.
It is important to remember that the tolerance should not be too large on
general metal cladding work ( a general tolerance of ±1mm is acceptable) as the
assembly and finish of the work could be sloppy.

2.4 Use of a Plumb-Line and Spirit Level

Refer to module 5 – unit 1 – Measuring: Ductwork and other large areas.

2.5 Accurate Centre Finding

Refer to module 5 – unit 1 – Measuring: Ductwork and other large areas.

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2.6 Calculation and Application of Insulation

Allowances
As mentioned earlier in section 1.1 of this unit, the insulation/cladding
diameter is calculated by taking the outside diameter of the pipe and adding two
thicknesses of insulation. The diameter of the insulation can b used for the
diameter of the metal cladding but it is usual practice to increase the diameter
of the metal cladding to facilitate fitting of the cladding over the insulation on
site. The chart below includes details of pipe size, insulation thickness and
circumferences of cladding to suit various insulation thicknesses. These are
suggested circumferences only and may vary.
Pipe ø Insulation Thickness
25 30 40 50 60 70 80 90
21 235 265 330 390 450 520 580 650
27 260 280 350 415 475 540 595
34 285 310 370 425 500 550 615 685
42 330 335 410 460 525 570 630 720
48 325 350 420 480 550 580 655 730
60 370 395 450 520 590 635 710 770
76 400 440 510 580 610 700 750
89 460 485 540 610 680 735 820 850
102 520
114 540 565 620 710 760 815 880 960
141 580 660 740 780 870 910 970
168 710 800 870 920 1030 1070 1145
194 770 900 960 1000 1060 1160
219 820 910 965 1040 1110 1180 1230 1290
245 1310
273 1050 1070 1120 1190 1270 1330 1390 1470
324 1200 1260 1315 1380 1440 1490 1570 1620
356 1290 1350 1390 1470 1560 1590 1670 1720
406 1550 1620 1690 1750 1820 1880
456 1620 1720 1800 1840 1910 1975
508 1770 1860 1950 1985 2060 2150
610 2190 2200 2250 2360 2400 2460

2.7 Area Calculation

Refer to module 5 – unit 1 – section 2.1.

2.8 Joint Positioning in Insulation and Cladding

The positioning of joints in cladding applications should conform to BS
5970:2001 and to the recommendations in earlier notes.
Refer to module 5 – unit 1 – section 1.8.

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2.9 Obstacle Location on Pipe-Work

Obstacles on pipe-work come in many forms such as hangers, steelwork
supports, other pipe-work close by or from the building structure itself. These
obstacles slow down the installation of the insulation and cause extra work by
way of measuring, cutting and fitting of metal cladding. The figures below show
some of the obstacles which the Industrial insulator may expect to see.
Refer to module 5 – unit 1 – section 1.9.

Note: Where cladding has to be cut away it shall fit closely to the pipe and be
completely waterproof.

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3.0 Measuring Pipe-work and job

Planning
Key Learning Points
 Use and care of appropriate measuring equipment
 Job planning and sequencing
 Works specification and drawings interpretation.

3.1 Use and Care of Measuring Equipment

Industrial insulators use many different types of measuring tools in the daily
performance of their duties. Where exact measurements are required a vernier
calliper is used. This instrument is accurate to 0.02 of a millimetre. It is
important to keep a vernier calliper clean and lightly oiled at all times. Make
sure they are always stored in a case or box when not in use, to protect them
from damage. Never clean any part of a vernier calliper with an emery cloth or
any type of abrasive substance.
On the other hand, where accuracy is not extremely critical, a common steel
rule, tape rule or folding rule will suffice for most measurements. These tools
are available in various lengths and come in both imperial and metric versions.
The figure below shows pipes been measured with a steel rule and a tape rule.

Measuring pipe-work with a tape rule and a steel rule(imperial measurements).

Handle steel rules and measuring tapes carefully. Lightly oil steel rules
frequently to prevent rust. Never allow the edges of measuring devices to
become nicked by striking them with hard edges. If a measuring tape becomes
nicked or broken in any way replace it immediately to avoid injury. Keep all
measuring tools in a toolbox when not in use. Avoid kinking measuring tapes
by pulling them straight out of their cases – do not bend them backwards.
After use, guide the tape back into its case by hand. O not use the hook as a
stop. Slow the tape down as you reach the end.

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3.2 Pipe Circumferences

To measure the circumference of a pipe, you must use a flexible type rule that
will conform to the shape of the pipe. A flexible steel tape rule is adaptable to
this job. When measuring the pipe, make sure the tape is wrapped squarely
around the axis of the pipe to ensure the measurement is not more than the
actual circumference of the pipe. This is extremely important when measuring a
large diameter pipe or vessel. Hold the rule or tape as shown in the figure
above. Take the reading, using a 2" graduation, for example, as the reference
point. In this case the correct reading is found by subtracting 2 inches from the
actual reading. In this case the first 2 inches of the tape, serving as a handle, will
enable you to hold the tape securely.

Pipe Diameters
The figure above shows the end of the rule lined up with one side of the pipe,
using your thumb as a stop. Then, with one end held in place, swing the rule
through an arc and take the maximum reading at the other side of the pipe. For
most purposes, the measurement obtained by using this method is satisfactory.
It is necessary you know how to take this measurement, as the outside diameter
of a pipe is very important to know as the inside diameter of the pipe insulation
conforms to this size.

3.3 Callipers
Inside and outside calliper are used in conjunction with a rule to determine the
thickness or the diameter of a surface, or the distance between surfaces. The
figure below shows some of the callipers available:

Outside Callipers. Inside Callipers.

A calliper is usually used in one of two ways. Firstly, take the dimension of the
component using an inside or outside callipers, and measure the distance
between the calliper legs using a steel rule.
Secondly, set the callipers to a certain distance and machine or work the part
until it checks with the dimension set up on the calliper.
It is import that good care is taken when using callipers. Keep callipers lightly
oiled, but do not over oil the joint of firm joint callipers or you may have
difficulty in keeping them tight. Always store callipers in a toolbox when not in
use.

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3.4 Job Planning, Teamwork and Record

Keeping
Measuring large jobs on site may require a number of people to work together
to gather the information required to manufacture and install the job. It is
important that these people work together as a team in order to gather the
information in a systematic and precise manner. A breakdown in
communication between team members can be detrimental to the success of
the overall completion and quality of the job.
Measuring large jobs and recording the data gathered in a clear and concise
manner is the most important task of the whole job. If the records of the data
gather is not correct or presented in a clear manner, mistakes will be made.
These mistakes can be very costly both in time and money.
Planning the job thoroughly from start to finish is vitally important. Team
members must know from the start their exact role within the team. A team
leader should be appointed from the start. This person would usually be the
most experienced member and it is his/her job to delegate tasks to other
members. Communication skills and the ability to communicate to people in a
clear and concise manner is vitally important.
A vital part of job planning and works sequencing is understanding the works
specification and interpreting the works drawings completely. Failure at this
point in not fully understanding the task ahead can be disastrous. It is
paramount that if a drawing or specification is unclear, that further information
and clarification is sought from the engineer or architect.

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Summary
Industrial pie-work systems carry various substances including gases, liquids
vapours and powders. These systems have to be extremely robust in order to
cope with the stresses and strains imposed on them by heat, cold, acidic
substances and corrosion.
A pipeline or pipe-work system is usually made up of various diameter pipes
and fittings. These fittings would include 90 and 45 degree radius bends,
reducers (concentric and eccentric), tees (equal and unequal), hangers and
supports, and various types of valves to regulate and control flow.
Pipe is specified by stating its nominal size and it should be noted particularly
that the nominal size is only approximate, and is neither the inside or the
outside diameter and standard tables or manufacturers’ tables should be used to
ascertain exactly these two dimensions.
Various tools are used to measure both the inside and outside diameters of pipe
and tube. These tools include a steel rule, a tape rule, an inside and outside
callipers. Care should be taken when using these tools and regular maintenance
such as the oiling of joints is important to ensure continuous operation of the
tools.
Insulation and cladding is applied to pipe-work and tubes to control heat loss
or gain, for protection against frost and other environmental elements and to
protect personnel from injury.
Planning and organisation is vitally important when measuring a large insulation
and cladding job. Communication between people and the delegation of tasks
will ensure the smooth running of the job. Record keeping, filing of drawings,
notes and understanding the works specification are all very important aspects
of any job, and a system should be in place whereby information is available in
a clear and concise and organised manner.

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Castleforbes Road
Dublin 1